Process for fluid catalytic cracking

ABSTRACT

One exemplary embodiment can be a process for fluid catalytic cracking The process can include providing a mixture of a fuel gas and at least one of steam and nitrogen to a catalyst stripping zone of a reaction zone. Usually, the fuel gas is added in an amount effective to add heat duty to a regeneration zone for a catalyst of the reaction zone.

FIELD OF THE INVENTION

This invention generally relates to a process for fluid catalytic cracking.

DESCRIPTION OF THE RELATED ART

Fluid catalytic cracking (may be abbreviated as “FCC”) can create a variety of products from heavier hydrocarbons. Often, a feed of heavier hydrocarbons, such as a vacuum gas oil, is provided to a fluid catalytic cracking reactor. Various products may be produced, including a gasoline product and/or another product, such as at least one of propylene and ethylene.

When operating FCC units with low coke accumulation on spent catalyst, the regenerator temperature may be too low to promote proper combustion. As such, high levels of carbon monoxide and/or nitrous oxide emissions may result. In order to mitigate these emissions, many refiners reduce the stripping steam rate to allow more hydrocarbons to enter the regenerator. These hydrocarbons can combust in the regenerator and increase its temperature. However, reduction of the stripping steam flow may have undesirable consequences in the spent catalyst stripper. Typically, steam distributors have a minimum flow rate and a differential pressure in order to distribute the stripping steam evenly. Reducing steam flow can cause uneven distribution of the steam in the stripper, and may lead to failure of mechanical components and/or plugging of the steam distributor jets.

SUMMARY OF THE INVENTION

One exemplary embodiment can be a process for fluid catalytic cracking The process can include providing a mixture of a fuel gas and at least one of steam and nitrogen to a catalyst stripping zone of a reaction zone. Usually, the fuel gas is added in an amount effective to add heat duty to a regeneration zone for a catalyst of the reaction zone.

Another exemplary embodiment may be a process for fluid catalytic cracking The process may include providing an effective amount of a mixture of a fuel gas stream and at least one of steam and nitrogen to a spent catalyst conduit communicating spent catalyst from a reaction zone to a regeneration zone.

Yet another exemplary embodiment can be a process for fluid catalytic cracking The process can include mixing a fuel gas and steam, providing the mixture to a catalyst stripping zone of the reaction zone, and passing the catalyst and mixture to the regeneration zone. Typically, the fuel gas is added in an amount effective to add heat duty to a regeneration zone for a catalyst of a reaction zone.

Generally, stripping steam not only displaces the hydrocarbon vapors in the voids between catalyst particles, but stripping steam may also react with the coke on the catalyst, further reducing the coke that enters the regenerator. Mixing steam with the fuel gas, which can include or consist of a recycle off-gas from an FCC unit, may enhance or replace part of the stripping steam flow rate.

The benefits provided by the embodiments herein can include increasing the recovery of heavier hydrocarbons and/or some coke by replacing heavier hydrocarbons and coke combustion with fuel gas combustion. Typically, more fuel gas within an emulsion phase enters the regenerator reducing the reaction of heavier hydrocarbons on the spent catalyst with the steam. Thus, the fuel gas may displace stripped higher value heavier hydrocarbons having a higher value than fuel gas. Other benefits may include maintaining the volume flow of stripping steam to maintain the stripping steam differential pressure in the distributors, thereby preventing plugging.

DEFINITIONS

As used herein, the term “stream” can include various hydrocarbon molecules, such as straight-chain, branched, or cyclic alkanes, alkenes, alkadienes, and alkynes, and optionally other substances, such as gases, e.g., hydrogen, or impurities, such as heavy metals, and sulfur and nitrogen compounds. The stream can also include aromatic and non-aromatic hydrocarbons. Furthermore, a superscript “+” or “−” may be used with an abbreviated one or more hydrocarbons notation, e.g., C3⁺or C3⁻, which is inclusive of the abbreviated one or more hydrocarbons. As an example, the abbreviation “C3⁺” means one or more hydrocarbon molecules of three carbon atoms and/or more.

As used herein, the term “zone” can refer to an area including one or more equipment items and/or one or more sub-zones. Equipment items can include one or more reactors or reactor vessels, heaters, exchangers, pipes, pumps, compressors, and controllers. Additionally, an equipment item, such as a reactor, dryer, or vessel, can further include one or more zones or sub-zones.

As used herein, the term “rich” can mean an amount of at least generally about 50%, and preferably about 70%, by mole, of a compound or class of compounds in a stream.

As used herein, the term “substantially” can mean an amount of at least generally about 80%, preferably about 90%, and optimally about 99%, by mole, of a compound or class of compounds in a stream.

As depicted, process flow lines in the FIGURE can be referred to interchangeably as, e.g., lines, pipes, feeds, products, or streams.

BRIEF DESCRIPTION OF THE DRAWING

The FIGURE depicts an exemplary fluid catalytic cracking apparatus.

DETAILED DESCRIPTION

Referring to the FIGURE, a fluid catalytic cracking apparatus 100 can include a reaction zone 120 and a regeneration zone 200. The reaction zone 120 can include a riser 130 that terminates inside a casing 140, in turn inside a shell 150, and a stripping zone 160. Generally, the casing 140 can be a riser termination device, such as vortex disengaging chamber, to separate hydrocarbon from a catalyst. Any suitable catalyst may be utilized including a mixture of a plurality of catalysts including an MFI zeolite and a Y-zeolite. Exemplary catalyst mixtures are disclosed in, e.g., U.S. Pat. No. 7,312,370.

Generally, the shell 150 surrounds the casing 140 and at least a portion of the riser 130. The shell 150 can also contain one or more cyclone separators 154 that can be in communication with a plenum 158. A line 170 can communicate one or more reaction products from the reaction zone 120. Exemplary reaction vessels and regenerators are disclosed in, e.g., U.S. Pat. No. 7,261,807; U.S. Pat. No. 7,312,370; and US 2008/0035527. However, it should be understood that any suitable reactor may be utilized with the embodiments disclosed herein.

Spent catalyst can fall from the shell 150 into the catalyst stripping zone 160. The catalyst stripping zone 160 can include one or more baffles 164. Alternatively, structured packing may be used in the stripping zone 160. Often, a stream 180 including steam and/or nitrogen is provided to the catalyst stripping zone 160.

In this exemplary embodiment, a fuel gas in any effective amount to provide the requisite heat duty to the regeneration zone 200 can be passed as a fuel gas stream 184 through a valve 186. A mixed stream 190, which may serve as at least a part of a stripping medium, including fuel gas and steam can be provided to the catalyst stripping zone 160.

Typically, coke bonded to the pores of the catalyst, which cannot be removed with the stripping medium, may be referred to as “hard coke” or “catalytic coke”. Often, strippable coke may be referred to as “soft coke”, “catalyst circulation coke”, or “heavier hydrocarbons” and are hydrocarbon gases and/or dispersions within void spaces of and within the interstitial spaces between catalyst particles. From a heat balance perspective, any hydrocarbon burning in the regeneration zone 200 may be referred to as “coke” from a heat balance perspective. However, the embodiments disclosed herein minimize the product material burning in the regeneration zone 200.

In this exemplary embodiment, the stream 180 includes steam although nitrogen may be used instead of or in addition to the steam. In at least one exemplary embodiment, at least a portion of the mixed stream 190 including the fuel gas is carried over to a spent catalyst conduit 174, as hereinafter described.

The fuel gas can include hydrogen, one or more C1-C4 hydrocarbons, preferably hydrogen and C1-C2 hydrocarbons. In other words, the fuel gas can include at least one of hydrogen, nitrogen, carbon monoxide, methane, ethane, ethene, propane, propene, butane, and butene, preferably at least one of hydrogen, methane, ethane, and ethene. The fuel gas stream can include or consist of a recycle off-gas from an FCC unit, or be obtained from other suitable sources within a refinery or a chemical manufacturing plant. Generally, heavier hydrocarbons require more molecules due to their weight and provide insufficient volume. As a consequence, it is desirable to use lighter molecules such as hydrogen, methane, and ethane versus heavier molecules such as butane, pentane, and nitrogen. Usually, the fuel gas can be at a pressure of about 340-about 1,400 kPa, and the steam can be at a pressure of no more than about 620 kPa and a temperature of no more than about 180° C. Typically, the volume of fuel gas can be about 0-about 100% of the mixed stream 190, preferably about 40-about 60%, by volume, of the mixed stream 190. Generally, the mixed stream 190 includes a weight ratio of fuel gas and steam in an amount of about 1:100-about 100:1, preferably about 1:2-about 2:1. The weight ratio of steam to fuel gas can be adjusted as conditions require. Generally, the fuel gas can be substantially the same composition as a lift gas utilized in an FCC unit provided at a base of a riser to lift and accelerate catalyst to a fuel injection point.

The regeneration zone 200 can include a combustor 220 and a separator 250, which collectively may form a regeneration vessel 210. Generally, a heater can provide the requisite heat of combustion inside the combustor 220. The combustor 220 can extend upward terminating in a separation or distributing device 254, which can include one or more arms. In addition, the separator 250 can substantially enclose the distributing device 254 and one or more cyclone separators 256 that separate entrained catalysts from one or more gases. The one or more cyclone separators 256 can be, in turn, in communication with a plenum 258 for receiving the one or more gases separated from the one or more cyclone separators 256. A line 260 can communicate a flue gas from the regeneration zone 200.

The spent catalyst conduit 174 can communicate the reaction zone 120 with the regeneration zone 200 for transferring spent catalyst to the combustor 220. The catalyst can rise in the combustor 220 with the coke and fuel gas undergoing combustion. Regenerated catalyst falling from the distributing device 254 can be communicated by a regenerated catalyst conduit 252 from the separator 250 of the regeneration zone 200 to the riser 130 of the reaction zone 120.

Alternatively or additionally, a fuel gas stream 192, having a similar composition as described above for the fuel gas stream 184, can be provided, preferably directly, to the spent catalyst conduit 174 in an amount effective for providing the requisite heat duty to the combustor 220. Optionally, the fuel gas stream 192 may include steam and/or nitrogen and can include at least one of nitrogen, steam, and one or more C2-C4 hydrocarbons. It should be understood that the fuel gas can be provided in the fuel gas stream 184 and/or as the fuel gas stream 192. The fuel gas stream 192 may serve as a fluidizing gas with respect to the spent catalyst present in the spent catalyst conduit 174.

The addition of fuel gas lines upstream of the stripping steam and/or lift distributor can require additional piping. The provision of check valves can prevent steam from entering the fuel gas and vice-versa. Moreover, additional equipment can include flow controllers and control valves that can adjust the ratio of steam to fuel gas. Generally, the fuel gas flow rate is monitored, as it will be considered a “feed” to the FCC apparatus 100. Optionally, a recycle stream of fuel flow gas may also be utilized.

In operation, a hydrocarbon feed 110, that may include at least one of a gas oil, a vacuum gas oil, an atmospheric gas oil, a coker gas oil, a hydrotreated gas oil, a hydrocracker unconverted oil, and an atmospheric residue, can be provided to the riser 130. The hydrocarbon feed 110 can also be contacted with regenerated catalyst provided by the regenerated catalyst conduit 252 at the base of the riser 130. Generally, the regenerated catalyst and feed mixture can be at a temperature of about 500-about 650° C. and a pressure of about 110-about 450 kPa. The catalyst and feed can rise within the riser 130 and separate at the casing 140 using any suitable device, such as swirl arms. Typically, the catalyst falls toward the base of the shell 150 while product gases rise and separate from catalyst in the one or more cyclone separators 154. Recovered catalyst can fall to the base of the shell 150 while the product gases may enter the plenum 158 and exit as a product stream 170. The hydrocarbon products can be further processed, such as in downstream fractionation zones. An exemplary fractionation zone is disclosed in, e.g., U.S. Pat. No. 3,470,084.

The regeneration zone 200 can receive spent catalyst through the spent catalyst conduit 174. Spent catalyst can enter the combustor 220 near its base where a first stream 208, typically including oxygen, is provided. Often, the first stream 208 includes air. The combustor 220 can operate at any suitable temperature, such as at least about 650° C. or other suitable conditions for removing coke accumulated on the catalyst particles.

Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.

In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.

From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. 

1. A process for fluid catalytic cracking, comprising: providing a mixture of a fuel gas and at least one of steam and nitrogen to a catalyst stripping zone of a reaction zone wherein the fuel gas is added in an amount effective to add heat duty to a regeneration zone for a catalyst of the reaction zone.
 2. The process according to claim 1, wherein the mixture comprises the fuel gas and steam.
 3. The process according to claim 2, wherein the weight ratio of the fuel gas and steam in the mixture is about 1:100-about 100:1.
 4. The process according to claim 2, wherein the weight ratio of the fuel gas and steam in the mixture is about 1:2-about 2:1.
 5. The process according to claim 1, wherein the fuel gas comprises at least one of hydrogen, nitrogen, carbon monoxide, methane, ethane, ethene, propane, propene, butane, and butene.
 6. The process according to claim 1, wherein the fuel gas comprises at least one of hydrogen, methane, ethane, and ethene.
 7. The process according to claim 1, wherein the catalyst stripping zone comprises one or more baffles.
 8. The process according to claim 1, further comprising providing the catalyst to the catalyst stripping zone, wherein the catalyst comprises an MFI zeolite.
 9. The process according to claim 8, wherein the regeneration zone further comprises a regeneration vessel receiving a spent catalyst communicated by a conduit.
 10. The process according to claim 9, further comprising providing a fuel gas stream to the conduit communicating the spent catalyst to the regeneration vessel.
 11. The process according to claim 1, further comprising providing a feed comprising at least one of a gas oil, a vacuum gas oil, an atmospheric gas oil, a coker gas oil, a hydrotreated gas oil, a hydrocracker unconverted oil, and an atmospheric residue to a riser of the reaction zone.
 12. The process according to claim 1, further comprising providing a plurality of catalysts, in turn comprising an MFI zeolite and a Y-zeolite.
 13. A process for fluid catalytic cracking, comprising: providing an effective amount of a mixture of a fuel gas stream and at least one of steam and nitrogen to a spent catalyst conduit communicating spent catalyst from a reaction zone to a regeneration zone.
 14. The process according to claim 13, wherein the mixture is provided to the catalyst stripping zone, and the mixture passes to the spent catalyst conduit.
 15. The process according to claim 13, wherein the mixture is provided directly to the spent catalyst conduit.
 16. The process according to claim 13, wherein the fuel gas stream comprises at least one of nitrogen, steam, and one or more C2-C4 hydrocarbons.
 17. The process according to claim 13, wherein the catalyst comprises an MFI zeolite.
 18. A process for fluid catalytic cracking, comprising: A) mixing a fuel gas and steam wherein the fuel gas is added in an amount effective to add heat duty to a regeneration zone for a catalyst of a reaction zone; B) providing the mixture to a catalyst stripping zone of the reaction zone; and C) passing the catalyst and mixture to the regeneration zone.
 19. The process according to claim 18, wherein a weight ratio of the fuel gas and steam in the mixture is about 1:100-about 100:1.
 20. The process according to claim 18, wherein a weight ratio of the fuel gas and steam in the mixture is about 1:2-about 2:1. 